Electrode Assembly Interference Fit to Prevent Lead Detachment
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Solution Overview
Problem
Aerosol provision systems, such as e-cigarettes, face issues with lead detachment causing short-circuits and the risk of liquid leakage due to the fluid transport path within the cartridge, leading to undesirable leakage and user inconvenience.
Innovation Solution
The use of an assembly where the lead is secured inside an aperture using an interference fit method, eliminating the need for crimping and reducing surface imperfections and fluid leakage, by deforming the body to engage with the lead section, thereby enhancing the mechanical and fluid-tight connection between the electrode and the aperture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead is attached to the electrode using conventional methods (soldering, crimping), then the electrical connection is established, but the lead may become detached during use causing short-circuits and faulty operation
Solution Approach 1:
The patent replaces conventional mechanical attachment methods (soldering, crimping) with an interference fit mechanism. The lead has a section with a larger diameter than the aperture, creating a mechanical interference fit that secures the lead to the electrode without requiring additional mechanical fastening processes. This eliminates the risk of lead detachment while avoiding the complexity and potential failure points of soldering or crimping operations.
2Strength
If crimping is used to secure the lead, then the connection is strengthened, but surface imperfections are created on the electrode which may affect performance
Solution Approach 1:
Instead of deforming the electrode to secure the lead (crimping), the patent inverts the approach by having the lead deform or engage with the electrode through an interference fit. The lead's larger diameter section is inserted into the aperture, and the electrode material elastically deforms to accommodate and secure the lead, rather than the electrode being crimped. This preserves the electrode's surface integrity while achieving strong mechanical and electrical connection.
3Ease of operation
If the cartridge contains a fluid transport path for liquid aerosol precursor, then the heating element can be supplied with liquid, but there is a risk of liquid leaking from the cartridge
Solution Approach 1:
The patent utilizes the elastic deformation capability of the cartridge body material to create a flexible seal around the lead. As the lead is inserted into the aperture, the body material elastically deforms to conform to the lead's shape and secure it tightly, creating a fluid-tight barrier. This flexible sealing mechanism prevents liquid leakage along the lead interface while maintaining the fluid transport path functionality, eliminating the need for rigid sealing components that could fail.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution securely attaches the electrodes without crimping, reducing mechanical weaknesses and leakage, ensuring reliable operation and user safety by preventing unwanted fluid leakage.
Implementation Method 1
a section of the lead (12) is secured inside the aperture (52) by an interference fit between the body (50) and an portion (54) of the electrode (10)
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
An assembly comprising a body (50) defining an aperture (52), and an electrode (10) comprising a portion (54) within the aperture (52), the assembly further comprising a lead (12) comprising a section (56) which is secured inside the aperture (52) by a first interference fit between the body (50) and the portion (54) of the electrode (10). The aperture (52) may comprise a first open end (58) and a second open end (60), wherein the electrode (10) extends through the first open end (58), and the lead (12) extends through the second open end (60). In which case, the electrode (10) may plug the first end (58) by a second interference fit between the body (50) and the (portion (54) of the electrode (10). The portion (54) of the electrode (12) may comprise a tapered section (62) against which the section (56) of the lead (12) is secured.